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60PFR PLUNGER PUMP SERVICE MANUAL

60 FRAME SPLIT MANIFOLD

6747, 6760, 6761, 6767

SPECIFICATIONS: Maximum specifications refer to individual attributes. It is not
implied that all maximums can be performed simultaneously. If more than one
maximum is considered, check with your CAT PUMPS supplier to confirm the proper
performance and pump selection. Refer to individual pump Data Sheet for complete
specifications, parts list and exploded view.

LUBRICATION: Fill crankcase with special CAT PUMP oil per pump specifications
[60FR-10 Qts.]. DO NOT RUN PUMP WITHOUT OIL IN CRANKCASE. Change ini-
tial fill after 50 hours running period. Thereafter, change oil every 3 months or 500
hour intervals. Additional lubrication may be required with increased hours of oper-
ation and temperature.

PUMP ROTATION: Pump was designed for forward rotation to allow optimum
lubrication of the crosshead area. Reverse rotation is acceptable if the crankcase oil
level is increased slightly above center dot to assure adequate lubrication.

PULLEY SELECTION: Select size of motor pulley required to deliver the desired
flow from Horsepower Requirement and Pulley Selection Chart (refer to Tech Bulletin
003 or individual Data Sheet).

DRIVE SELECTION: The motor or engine driving the pump must be of adequate
horsepower to maintain full RPM when the pump is under load. Select the electric
motor from the Horsepower Requirement Chart according to required pump
discharge flow, maximum pressure at the pump and drive losses of approximately
3-5%. Consult the manufacturer of gas or diesel engine for selection of the proper
engine size.

MOUNTING: Mount the pump on a rigid, horizontal surface in a manner to permit
drainage of crankcase oil. An uneven mounting surface will cause extensive dam-
age to the pump base. To minimize piping stress, use appropriate flexible hose to
inlet and discharge ports. Use the correct belt; make sure pulleys are aligned.
Excessive belt tension may be harmful to the bearings. Hand rotate pump before
starting to be certain shaft and bearings are free moving.

LOCATION: If the pump is used in extremely dirty or humid conditions, it is recom-
mended pump be enclosed. Do not store or operate in excessively high temperature
areas or without proper ventilation.

INLET CONDITIONS: Refer to complete Inlet Condition Check-List in this manual
before starting system. DO NOT STARVE THE PUMP OR RUN DRY.
Temperatures above 130°F are permissible. Add 1/2 PSI inlet pressure per each
degree F over 130°F. Elastomer or RPM changes may be required. See Tech
Bulletin 002 or call CAT PUMPS for recommendations

C.A.T.: Installation of a C.A.T. (Captive Acceleration Tube) is recommended in appli-
cations with stressful inlet conditions such as high temperatures, booster pump
feed, long inlet lines or quick closing valves.

DISCHARGE CONDITIONS: OPEN ALL VALVES BEFORE STARTING SYSTEM to
avoid deadhead overpressure condition and severe damage to the pump or system.

Install a Pulsation Dampening device on the discharge head or in the discharge line
as close to the head as possible. Be certain the pulsation dampener (Prrrrr-o-lator) is
properly precharged for the system pressure (see individual Data Sheet.)

A reliable Pressure Gauge should be installed near the discharge outlet of the high
pressure manifold. This is extremely important for adjusting pressure regulating
devices and also for proper sizing of the nozzle or restricting orifice. The pump is
rated for a maximum pressure; this is the pressure which would be read at the
discharge manifold of the pump, NOT AT THE GUN OR NOZZLE.

Use PTFE thread tape or pipe thread sealant (sparingly) to connect accessories or
plumbing. Exercise caution not to wrap tape beyond the last thread to avoid tape from
becoming lodged in the pump or accessories. This condition will cause a malfunction
of the pump or system.

PRESSURE REGULATION: All systems require both a primary pressure regulating
device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e.,
pop-off valve, safety valve). The primary pressure device must be installed on the
discharge side of the pump. The function of the primary pressure regulating device
is to protect the pump from over pressurization, which can be caused by a plugged
or closed off discharge line. Over pressurization can severely damage the pump,
other system components and can cause bodily harm. The secondary safety relief
device must be installed between the primary device and pump. This will ensure
pressure relief of the system if the primary regulating device fails. Failure to install
such a safely device will void the warranty on the pump.

If a large portion of the pumped liquid is by-passed (not used) when the high
pressure system is running, this by-pass liquid should be routed to an adequately
sized, baffled supply tank or to drain. If routed to the pump inlet, the by-pass liquid
can quickly develop excessive heat and result in damage to the pump. A tem-
perature control device to shut the system down within the pump limits or multiple
THERMO VALVES must be installed in the by-pass line to protect the pump.

NOZZLES: A worn nozzle will result in loss of pressure. Do not adjust pressure
regulating device to compensate. Replace nozzle and reset regulating device to
system pressure.

PUMPED LIQUIDS: Some liquids may require a flush between operations or
before storing. For pumping liquids other than water, contact your CAT PUMPS
supplier.

STORING: For extended storing or between use in cold climates, drain all pumped
liquids from pump and flush with antifreeze solution to prevent freezing and
damage to the pump. DO NOT RUN PUMP WITH FROZEN LIQUID (refer to Tech
Bulletin 083).

INSTALLATION AND START-UP INFORMATION

Optimum performance of the pump is dependent upon the entire liquid system and will be obtained only
with the proper selection, installation of plumbing, and operation of the pump and accessories.

PN 30051 Rev F 7254

WARNING

All systems require both a primary pressure regulating device (i.e., regulator, unloader) and a secondary pressure safety relief device (i.e., pop-off valve, safety valve).
Failure to install such relief devices could result in personal injury or damage to the pump or to system components. CAT PUMPS does not assume any liability or responsibility
for the operation of a customer’s high pressure system.

Products described hereon are covered by one or more of the following U.S. patents 3558244, 3652188, 3809508, 3920356, 3930756 and 5035580

CAT PUMPS (U.K.) LTD.

1 Fleet Business Park, Sandy Lane, Church Crookham, Fleet

Hampshire GU52 8BF, England

Phone Fleet 44 1252-622031 — Fax 44 1252-626655

e-mail: [email protected]

N.V. CAT PUMPS INTERNATIONAL S. A.

Heiveldekens 6A, 2550 Kontich, Belgium

Phone 32- 3- 450.71.50 — Fax 32-3- 450.71.51

e-mail: [email protected] www.catpumps.be

CAT PUMPS DEUTSCHLAND GmbH

Buchwiese 2, D-65510 Idstein, Germany